High-efficiency filter device and method for making same

ABSTRACT

A high-efficiency filter for removing or collecting trace levels of chemical compounds includes a randomly oriented glass substrate, a primer coating and a carbon coating. The present filter is operable to sample or remove chemical compounds from the air with a high volumetric capacity while maintaining a low pressure drop across the filter substrate. A method for making the present filter includes providing a glass substrate with randomly oriented glass fibers which is treated to remove any glue or other substances; the substrate is then coated with a primer including polydimethylsiloxane; and the primed substrate is then coated with a carbonaceous compound including polydimethylsiloxane.

BACKGROUND OF THE INVENTION

This invention relates to filters for sampling or cleaning chemical compounds from the air and, more particularly, to a glass based filter for collecting volatile, semi-volatile and particulate phase chemical compounds from the air.

Air filtration devices are used primarily to clean air by removing particles and undesirable chemical odors. Secondarily, they are essential to air sampling technology for the determination of contaminants by collecting trace levels of chemical compounds. Air filter systems exist that are capable of collecting trace chemicals. Likewise, other air filter systems operate without a large pressure drop. However, at a practical level, a filter not only needs to collect chemical contaminants from the air, but it must do so without impeding the ventilation system in which it is installed. Therefore, a high capacity, low pressure drop filter capable of collecting volatile, semi-volatile and to a degree, particulate chemical compounds is needed.

Existing filter technology uses different substrates coated with, or created from activated carbon to collect chemical constituents from the air. These substrates include glass, paper and other fibers. It is well known in the art to coat these substrates with a coating including activated carbon. The activated carbon functions to “trap” or adsorb chemicals present in the air stream.

SUMMARY OF THE INVENTION

There is, therefore, provided in the practice of the invention a novel high-efficiency air filtration device and method of making the same for the collection of trace chemical constituents at a high linear face velocity and with a correspondingly low pressure drop. The high-efficiency filter includes a random glass substrate with a carbon coating. The high-efficiency filter can be used in sampling situations to collect trace chemicals, or as a filter or pre-filter to remove chemical compounds from the air.

In a preferred embodiment, a high-efficiency filter includes a random-strand, progressive denier, fiber-glass substrate and a carbon coating applied to the substrate. The carbon coating is applied in a manner to completely coat the glass substrate.

In another embodiment, the high-efficiency filter is made by thermally treating a random glass substrate to remove impurities, such as glue. The thermally cleaned substrate is then coated with a primer containing polydimethylsiloxane. Once the primer coat has dried, the carbon coating is applied.

Accordingly, it is an object of the present invention to provide an improved high-efficiency filter for use in sampling technologies to detect trace level chemical compounds.

It is a further object of the present invention to provide an improved method for making a high-efficiency filter for use in sampling technologies.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other inventive features, advantages, and objects will appear from the following Detailed Description when considered in connection with the accompanying drawing in which similar reference characters denote similar elements.

FIG. 1 is a side view of a high-efficiency filter constructed in accordance with the teachings of the present invention.

DETAILED DESCRIPTION

Referring to the drawings in greater detail, FIG. 1 shows a high-efficiency filter 20 constructed in accordance with a preferred embodiment of the present invention. The filter 20 includes a randomly oriented glass substrate, primer coat and carbon coating. The filter is operable to sample or remove chemical compounds from the air with a high volumetric capacity while maintaining a low pressure drop across the filter substrate.

In a preferred embodiment, the randomly oriented glass substrate, as shown in FIG. 1, is a laminate collection of biaxially oriented and randomly spun glass fibers of increasing denier with respect to the thickness of each laminate layer positioned into a cylindrical shape prior to the final compression into a disk for certain applications, or left in the shape of a cylinder for others. The glass substrate appears spherical due to the filter media's resistance to linear compression tangent to the fiber orientations. This low aspect ratio filter demonstrates this point. The fibers are alternately stacked in sheets of progressively dense layers positioned such that the densest layer is always “downstream” of a less dense layer. This is designated as the outlet 24 in FIG. 1. This arrangement provides for the extraordinary capacity of the filter to “breathe” while maintaining a tortuous network of adsorptive surface area for the air as it flows through the filter. The air enters the inlet 22 where the fibers are less dense. A good example of this configuration is the Front-Line Blue™ filter manufactured by the American Air Filter Corporation in Louisville, Ky. The glass fiber filters sold as the Front-Line Blue™ filter (one inch thick version) is coated with glue to maintain the glass fibers in the selected arrangement. To use the randomly oriented glass filter as the glass substrate, it must be treated to accept the carbon coating.

In a preferred embodiment, the glass substrate bundle is heated at approximately 280° C. to thermally clean the filter, removing any glue or other impurities. Alternatively, the thermal cleaning may occur at a temperature in the range of between approximately 100°-350° C. The glass substrate bundles are placed in alignment with the flow path 26 as shown in FIG. 1, and maintained in this position to easily identify the inlet 22 and outlet 24 side of the substrate. The substrate may be thermally cleaned in an air environment or an inert environment. Depending on the number of glass fiber filters being treated, the thermal cleaning usually takes 2 hours. The thermal cleaning takes place in a special vessel that includes a coiled sparging tube at the bottom to ensure the complete purging of volatilized constituents. In a preferred embodiment, sixteen (16) individual Front-Line Blue substrates are placed in a 30 quart pressure cooker to burn off the glue and any other impurities. The flow rate range for the thermal cleaning is 3-5 L/minute. The thermal cleaning treatment lasts approximately 2 hours. The substrate is cooled in this same vessel by continuing to flow air through the vessel.

After the glass substrate bundle is treated to remove the glue, it is ready to be primed. The substrate bundle is spray coated with a pre-weighed amount of polydimethylsiloxane (“PDMS”) dissolved in methylene chloride (“MECL”), preferably at a ratio of approximately 0.27 g PDMS per gram of MECL. Before the primer coat is applied to the substrate bundle, a small amount of a platinum catalyst is added to the primer (approximately 15 ul, and shaken vigorously). The primer should be applied using a thin-layer chromatography sprayer equipped with a 0.8 mm orifice. In one embodiment, while priming, the glass fibers of the filter are maintained at a temperature above the ambient dew point. The primer should be applied to the substrate bundle while it is heated at approximately 50° C., although heating between 20° C. and 40° C. will be adequate. Once the substrate bundle is coated with the primer, it is allowed to rest at room temperature for approximately one hour. The resting period should be at least 60 minutes and up to several hours.

After the primed substrate has rested at room temperature, the carbon coating is applied. The carbon coating consists of a carbonaceous adsorbent and polydimethylsiloxane, with a platinum catalyst. In a preferred embodiment, the carbonaceous adsorbent is a product available commercially as Carboxen™ 1006 from Supelco, Bellefonte, Pa. The carbon coating should be applied using a thin-layer chromatography sprayer equipped with a 0.8 mm orifice, although any similarly small spraying device should suffice. The carbon coating consists of approximately 2-5 microns carbon particles placed in PMDS. Initially apply the carbon coating at a 90 angle to the substrate. Then multiple passes of the coating at a 45° angle should be accomplished to promote the maximum amount of penetration to the interior core of the substrate.

The carbon coating may be reapplied until the desired thickness of coating is achieved. In a preferred embodiment, the carbon coating is approximately 5-75 microns. In a more preferred embodiment, the carbon coating is approximately 25-50 microns.

Once the carbon coating is applied, the filter is conditioned or cured at a temperature in the range of between about 100° C. to about 350° C. in a special second vessel. The second vessel is similar to the first vessel in that it uses a coiled sparge tube at the bottom to ensure that the entire air space within the vessel is adequately purged of any volatile compounds during the conditioning stage. The sparging gas must be inert and of ultra-high purity. In a preferred embodiment, the filter is conditioned at a temperature in the range of approximately 280° C. to approximately 300° C. In a preferred embodiment, the filter is conditioned for approximately 120 minutes, following a 60 minute hold at 40° C. The conditioning period may last from 120 minutes to multiple hours, depending upon scheduling. After conditioning, the filter is cooled in this same second vessel.

Once the coating on the substrate bundle has been conditioned, the substrate bundle may be placed in a filter canister. The substrate bundle is removed, noting the alignment of the bundle to identify inlet and outlet, and placed in a filter canister in alignment with the flow path of the filter canister.

In another embodiment, the filter is used as a pre-filter in combination with a HEPA filter. While HEPA filters are efficient collectors for particulate forms of a variety of toxic industrial chemicals and certain biological airborne particles as well, they are unsuitable to collect gas phase industrial chemicals. The filter of the present invention is designed to efficiently collect industrial chemical vapors. When the two filter types are combined, they effectively collect both particulate (chemical and certain biological) and gas phase chemical contaminants. The pre-filter is made according to the present invention and positioned in a housing that can be removably attached to a commercially available HEPA filter.

The high efficiency filter according to the present invention provides a high volume, low pressure drop device for collecting or removing chemical compounds from the environment.

Thus, an improved high-efficiency filter is disclosed which utilizes a novel randomly oriented glass substrate with a carbon coating for detecting or collecting chemical compounds. This invention allows for superior filtering or sampling with a high volume capacity and a low pressure drop across the filter substrate. While preferred embodiments and particular applications of this invention have been shown and described, it is apparent to those skilled in the art that many other modifications and applications of this invention are possible without departing from the inventive concepts herein. 

1. A high-efficiency filter comprising: a randomly oriented glass substrate; a primer coating including polydimethylsiloxane applied to the glass substrate; and at least one layer of carbon coating substantially covering the glass substrate, the carbon coating including polydimethylsiloxane.
 2. The filter according to claim 1 wherein the carbon coating consists of Carboxen™
 1006. 3. The filter according to claim 2 wherein the primer coating further includes a platinum catalyst.
 4. The filter according to claim 2 wherein the glass substrate includes glass fibers arranged so that the fibers on one side of the substrate are more densely positioned as compared to the fibers on the other side of the substrate.
 5. The filter according to claim 1 wherein said randomly oriented glass substrate is a laminate collection of biaxially oriented randomly spun glass fibers of increasing denier.
 6. The filter according to claim 5 wherein the glass fibers are alternately stacked in sheets of progressively dense layers.
 7. A high efficiency filter for removing particulates and chemical vapors from the air, comprising: a pre-filter assembly including at least one randomly oriented glass substrate, primed and coated with a carbonaceous adsorbent; a housing for containing the pre-filter assembly; a HEPA pleated aerosol filter with housing; and means associated with the pre-filter housing for removably attaching the pre-filter assembly to the HEPA filter housing.
 8. The filter according to claim 7 wherein said randomly oriented glass substrate is a laminate collection of biaxially oriented randomly spun glass fibers of increasing denier.
 9. The filter according to claim 8 wherein the glass fibers are alternately stacked in sheets of progressively dense layers.
 10. The filter according to claim 7 wherein the glass substrate is primed with a primer coating which includes polydimethylsiloxane.
 11. The filter according to claim 10 wherein the primer coating further includes a platinum catalyst.
 12. The filter according to claim 7 wherein the glass substrate includes glass fibers arranged so that the fibers on one side of the substrate are more densely positioned as compared to the fibers on the other side of the substrate.
 13. The filter according to claim 7 wherein the glass substrate is coated with a carbon coating which includes polydimethylsiloxane.
 14. A method for making a filter comprising the following steps: selecting a plurality of substrate bundles, each having progressively dense layers of glass fibers with a designated flow path therethrough; properly aligning the designated flow path of each substrate bundle with a flow path through a first vessel and placing the plurality of properly aligned substrate bundles in the first vessel; heating the first vessel and the substrate bundles to thermally clean the glass fibers of the plurality of substrate bundles, while flowing a gas through the first vessel; cooling the plurality of substrate bundles in the first vessel by flowing the gas through the first vessel; removing the thermally cleaned plurality of substrate bundles from the first vessel; applying a primer to the glass fibers of each substrate bundle to achieve a predetermined thickness; drying the primer on the glass fibers of each substrate bundle; applying a coating to the glass fibers of the substrate bundles to achieve a predetermined thickness; properly aligning the flow path of each coated substrate bundle with a flow path through a second vessel and placing a plurality of the properly aligned coated substrate bundles in the second vessel; heating the second vessel and the plurality of coated substrate bundles to condition the coating, while flowing a second gas through the second vessel; and cooling the plurality of coated substrate bundles in the second vessel by flowing the second gas through the second vessel.
 15. The method according to claim 14 wherein the substrate bundles are the glass fibers associated with a Front-Line Blue™ series filter.
 16. The method according to claim 14 wherein the first pressure vessel is heated for a predetermined time at a predetermined temperature.
 17. The method according to claim 16 wherein the predetermined time is approximately 2 hours and the predetermined temperature is approximately 280° C.
 18. The method according to claim 17 wherein the gas that flows through the first vessel is breathing grade air.
 19. The method according to claim 18 wherein the gas flows through the first vessel at a flow rate of approximately 3 lpm and at a pressure of approximately 5 psi.
 20. The method according to claim 14 wherein ambient air is preheated to above the ambient dew point and is passed through the substrate bundles during application of the primer.
 21. The method according to claim 20 wherein a pre-weighed amount of primer is applied to each substrate bundle.
 22. The method according to claim 21 wherein the primer is applied to each substrate bundle by spraying the primer through a thin-layer chromatography sprayer equipped with an orifice of approximately 0.8 mm.
 23. The method according to claim 22 wherein the primer includes polydimethylsiloxane dissolved in methylene chloride and a platinum catalyst is added.
 24. The method according to claim 23 wherein the coating is applied to each substrate bundle by spraying the coating through a thin-layer chromatography sprayer equipped with an orifice of approximately 0.8 mm to build up a coating thickness in the range of approximately 5-75 microns on the glass fibers.
 25. The method according to claim 24 wherein the coating includes a carbonaceous adsorbent.
 26. The method according to claim 25 wherein the carbonaceous adsorbent is Carboxen™
 1006. 27. The method according to claim 25 wherein the coating includes the carbonaceous adsorbent and polydimethylsiloxane mixed with platinum.
 28. The method according to claim 27 wherein the second vessel is heated for a predetermined time and a predetermined temperature.
 29. The method according to claim 28 wherein the predetermined time is approximately 2 hours and the predetermined temperature is in the range of approximately 100°-350° C.
 30. The method according to claim 28 wherein the predetermined temperature is in the range of approximately 280°-300° C.
 31. The method according to claim 28 wherein the second gas is ultra high purity nitrogen that flows through the second pressure vessel at a rate of approximately 3 lpm and at a pressure of approximately 5 psig.
 32. The method according to claim 14 further including the steps of removing at least one of the substrate bundles from the second vessel, properly aligning the designated flow path of the substrate bundle with a flow path of a single filter canister and placing the properly aligned substrate bundle in the filter canister.
 33. A method for making a coated glass fiber filter comprising the following steps: aligning a designated flow path of a progressively dense glass fiber filter bundle marketed under the trademark Front-Line Blue™ with a flow path of a first pressure vessel and placing a plurality of the properly aligned filter bundles in the first pressure vessel; preconditioning the filter bundles in the first pressure vessel wherein the preconditioning includes heating the pressure vessel to approximately 280° C. for approximately 2 hours and purging the pressure vessel with breathing grade air flowing in excess of 3 lpm at approximately 5 psig to thermally decompose and volatilize a ureaformaldehyde based glue in the filter bundles; cooling the filter bundles by flowing breathing grade air through the first pressure vessel until the filter bundles reach room temperature; removing the preconditioned filter bundles from the first pressure vessel; flowing air through each preconditioned filter bundle, said air having been preheated to a temperature sufficient to maintain the surface temperature of the filter bundle above the ambient dew point and applying a pre-weighed amount of primer to each filter bundle using a thin-layer chromatography sprayer equipped with a 0.8 mm orifice; resting the primed filter bundles for about one hour at room temperature; applying a coating to each primed filter bundle using a thin-layer chromatography sprayer equipped with a 0.8 mm orifice to build up a coating thickness in the range of approximately 5-75 microns on the glass fibers of each filter bundle; aligning the designated flow path of each coated filter bundle with a flow path of a second pressure vessel and placing a plurality of the properly aligned coated filter bundles in the second pressure vessel; heating the second pressure vessel at approximately 280° C. for approximately 2 hours while flowing ultra high purity nitrogen through the second pressure vessel at more than 3 lpm at approximately 5 psig; and cooling the coated filter bundles by flowing ultra high purity nitrogen at more than 3 lpm at approximately 5 psig through the second pressure vessel.
 34. The method according to claim 33 further including the steps of removing a cooled coated filter bundle from the second pressure vessel, aligning the designated flow path of the filter bundle with a proper flow path of a filter canister and placing the properly aligned coated filter bundle in the filter canister.
 35. A method for making a glass fiber filter bundle comprising the following steps: selecting at least one substrate bundle having progressively dense glass fibers with a designated flow path therethrough; aligning the designated flow path of the substrate bundle with a flow path through a first pressure vessel and placing a properly aligned substrate bundle in the first pressure vessel; heating the first pressure vessel to thermally clean the substrate bundle; cooling the substrate bundle in the first pressure vessel; removing the thermally cleaned substrate bundle from the first pressure vessel; applying a primer to the glass fibers of the substrate bundle while keeping the temperature above the ambient dew point; drying the primer on the substrate bundle; applying a coating to the glass fibers of the substrate bundle to achieve a predetermined thickness; aligning the designated flow path of at least one coated substrate bundle with a flow path through a second pressure vessel and placing at least one properly aligned coated substrate bundle in the second pressure vessel; heating the second pressure vessel to cure the coating on the substrate bundle; and cooling the substrate bundle in the second pressure vessel.
 36. The method according to claim 35 further including the steps of removing a cooled coated substrate bundle from the second pressure vessel, aligning the designated flow path of the filter bundle with a proper flow path of a filter canister and placing the properly aligned coated filter bundle in the filter canister.
 37. The method according to claim 35 wherein the at least one substrate bundle is a laminate collection of biaxially oriented randomly spun glass fibers of increasing denier.
 38. The method according to claim 37 wherein said glass fibers are alternately stacked in sheets of progressively dense layers.
 39. The method according to claim 35 wherein the first pressure vessel is heated to a predetermined temperature in the range of between 100°-350° C.
 40. The method according to claim 35 wherein the primer applied to the glass fibers of the substrate bundle includes polydimethylsiloxane.
 41. The method according to claim 35 wherein the primer applied to the glass fibers of the substrate bundle includes a pre-weighed amount of polydimethylsiloxane dissolved in methyllene chloride.
 42. The method according to claim 41 wherein the ratio of polydimethylsiloxane (PDMS) to methyllene chloride (MECL) is approximately 0.27 g PDMS per gram of MECL.
 43. The method according to claim 42 wherein the primer applied to the glass fibers of the substrate bundle include a platinum catalyst.
 44. The method according to claim 35 wherein the primer is applied to the glass fibers of the substrate bundle while the substrate bundle is heated to a temperature between approximately 20° C. and approximately 50° C.
 45. The method according to claim 35 wherein the coating applied to the glass fibers of the substrate bundle includes a carbonaceous adsorbent.
 46. The method according to claim 45 wherein the coating applied to the glass fibers of the substrate bundle includes polydimethylsiloxane.
 47. The method according to claim 46 wherein the coating applied to the glass fibers of the substrate bundle includes a platinum catalyst.
 48. The method according to claim 35 wherein the coating applied to the glass fibers of the substrate bundle is initially applied at a 90° angle to the substrate.
 49. The method according to claim 48 wherein subsequent applications of the coating applied to the glass fibers of the substrate bundle are applied at a 45° angle to the substrate.
 50. The method according to claim 35 wherein the coating applied to the glass fibers of the substrate bundle is in the range of approximately 5-75 microns.
 51. The method according to claim 35 wherein the second pressure vessel is heated to a predetermined temperature in the range of between approximately 100° C. to approximately 350° C.
 52. The method according to claim 51 wherein the second pressure vessel is heated for approximately two hours following a one hour hold at 40° C.
 53. A method for making a filter comprising the following steps: selecting a plurality of substrate bundles, each bundle being a progressively dense glass fiber arrangement having an inlet and an outlet; placing the plurality of substrate bundles in a first pressure vessel and properly aligning the inlet of each substrate bundle with a flow path through the first pressure vessel; heating the plurality of substrate bundles in the first pressure vessel to thermally clean the glass fibers of the plurality of substrate bundles, while flowing a gas through the first pressure vessel; cooling the plurality of substrate bundles in the first pressure vessel by flowing the gas through the first pressure vessel; removing the thermally cleaned plurality of substrate bundles from the first pressure vessel; applying a primer to the glass fibers of each substrate bundle to achieve a predetermined thickness range while maintaining the temperature of the glass fibers above the ambient dew point; drying the primer on the glass fibers of each substrate bundle; applying a coating to the glass fibers of each substrate bundle to achieve a predetermined thickness; placing the plurality of coated substrate bundles in a second pressure vessel and properly aligning the inlet of each substrate bundle with a flow path through the second pressure vessel; heating the plurality of coated substrate bundles in the second pressure vessel to condition the coating, while flowing a second gas through the second pressure vessel; and cooling the plurality of coated substrate bundles in the second pressure vessel by flowing the second gas through the second pressure vessel.
 54. The method according to claim 53 further including the steps of removing the plurality of coated substrate bundles from the second pressure vessel, properly aligning the inlet of a single substrate bundle with an inlet of a single filter canister and placing the properly aligned coated substrate bundle in the filter canister.
 55. A method for making a filter comprising the following steps: selecting a plurality of substrate bundles, each having progressively dense glass fibers with a designated flow path therethrough; placing the plurality of properly aligned substrate bundles in the first vessel; heating the first vessel and the substrate bundles to thermally clean the glass fibers of the plurality of substrate bundles, while flowing a gas through the first vessel; cooling the plurality of substrate bundles in the first vessel by flowing the gas through the first vessel; removing the thermally cleaned plurality of substrate bundles from the first vessel; applying a primer to the glass fibers of each substrate bundle to achieve a predetermined thickness; drying the primer on the glass fibers of each substrate bundle; applying a coating to the glass fibers of the substrate bundles to achieve a predetermined thickness; placing a plurality of the properly aligned coated substrate bundles in the second vessel; heating the second vessel and the plurality of coated substrate bundles to condition the coating, while flowing a second gas through the second vessel; and cooling the plurality of coated substrate bundles in the second vessel by flowing the second gas through the second vessel.
 56. A filter comprising: a randomly oriented glass substrate having progressively dense layers of glass fibers with a designated flow path therethrough; and at least one layer of a carbon coating substantially covering the glass substrate, the carbon coating including polydimethylsiloxane.
 57. The filter according to claim 56 wherein the carbon coating includes a platinum catalyst.
 58. The filter according to claim 56 wherein the carbon coating includes a carbonaceous adsorbent and a platinum catalyst.
 59. The filter according to claim 56 wherein the carbon coating has a thickness in the range of approximately 5-75 microns.
 60. The filter according to claim 56 including a primer coating applied to the glass substrate.
 61. The filter according to claim 60 wherein the primer coating includes polydimethysiloxane.
 62. The filter according to claim 60 wherein the primer coating includes polydimethylsiloxane dissolved in methylene chloride.
 63. The filter according to claim 62 wherein the primer coating further includes a platinum catalyst.
 64. The filter according to claim 62 wherein the ratio of polydimethylsiloxane to methylene chloride is approximately 0.27 g polyimethylsiloxane per gram of methylene chloride.
 65. The filter according to claim 56 including a filter canister enclosing the glass substrate. 